Process and apparatus for distributing fluid inerts with respect to the electrodes of a fuel battery

ABSTRACT

A FUEL BATTERY IS PROVIDED HAVING AN ELECTROLYTE ELEMENT, SUCH AS A MATRIX IMMOBILIZED ELECTROLYTE OR ION EXCHANGE STRUCTURE, CARRYING FIRST AND SECOND SEGMENTED ELECTRODES ON OPPOSITE FACES. THE ELECTRODE SEGMENTS ARE ELECTRICALLY SERIALLY RELATED. FLUID REACTANT IS DISTRIBUTED TO THE FIRST ELECTRODE SEGMENTS THROUGH ONE OR MORE CHANNELS WHICH DIRECT THE FLUID REACTANT TO FLOW SERIALLY ACROSS THE ELECTRODE SEGMENTS ALONG LATERALLY SPACED INTERCONNECTED COURSES WHICH ARE FREE OF INTERCONNECTION MEDIATE THEIR ENDS. THIS CAUSES FLUID INERTS PRESENT IN THE FLUID REACTANT TO BE COLLECTED IN THE TERMINAL COURSES SO THAT THE FLUID INERTS ARE DISTRIBUTED BETWEEN THE ELECTRODE SEGMENTS.   D R A W I N G

, D. w. CRAFT 3,554,809 PROCESS lAND APPARATUS FOR DISTRIBUTING FLUID INERTS WITH RESPECT TO ELECTRODES OF A FUEL BATTERY Filed Dec. las,v 1967-` 2 Sheets-Sheet l FIG.3.

INVENTOR: DONALD w. CRAFT, WM5@ Hl ATT RNEY.

2 Sheets-Sheet 2 .m mmmnmmm@ E D DE.

PROCESS ND APPRATUS FOR DISTRIBUTING FLUID INERTS v WITH RESPECT ATO THE ELECTRODES OF A FUEL BATTERY Filed DSC. 18, 1967 Jan; 12, 1971 f .sga-

yStates PatentO v Int. Cl. H01m 27/16 U.S. Cl. 13G-86 11 Claims ABSTRACT. oF THE DISCLOSURE 1 A fuel battery is provided having an electrolyte element, such as a matrix-immobilized electrolyte or ion exchange structure, carrying first and second segmented electrodes on opposite facesHI'he electrode segments are electrically serially related. Fluid reactant is distributed to the first electrode'segmentsthrough one or more channels Vwhich direct the fluid reactant to flow serially across the electrode segments along laterally spaced interconnected courses which arefree of interconnection mediate their ends. This causes fiuid inerts present in the fluid reactant toV be collected in the terminal courses so that the fluid inerts are distributed between the electrode segments.`

My invention pertains'to a process of distributing fluid inerts with respect to the electrodes of a fuel battery and to an improved fuel battery construction.

i VMy invention is an improvement on the invention of Holmes, Ser. No. 563,501, filed July 7, 1966, titled Moisture Conserving Convectively Fed Fuel Cell Unit. Holmes discloses 'a fuel battery provided with a central mounting frame which mounts two ion exchange membranes. The inner and outer faces-of the membranes carry laterally spaced electrode segments. These segments are electrically connected inseries. The ion exchange membranes and the mounting frame sealingly cooperate to form a chamber into which air is allowed to convectively flow at a controlled rate. A lfluid reactant, such as hydrogen, `is distributed to the'electrode segments lying on the outerfaces of `theion exchange' membranes. Also, heat is dissipated from the lfuel battery outwardly. To accom-r plish` thisa iluid'reactant distributor is l.mounted adjacent the outer facef'of each of the ion exchange membranes. The fiud distributor in the `preferred form is a metal frame carrying on its outer surfacevertical heat dissipation fins. To provide intimate contact between the metal frame and the outer electrode segments a plurality of platens-are provided which -press against the outer surface of the electrode segments. The platens are defined by two intersecting sets of parallel channels in the metal plate. The fluid reactant is then free to flow to the outer electrode segments through a number of multi-ply interconnected channels. Since the electrodes are porous and generally include as an outer layer foraminous elements, such as screens, the reactant is free to diffuse from the channels to the portionsof the electrode segments which bear against the platens. Electrical shorting of adjacent elec trode vsegments through the platens is prevented by a thin, thermallyvconductive, electrically insulative coating on the platens. The mounting of segmented electro-des on a unitary electrolyte structure is also discussed in detail by Dantowitz in p atent application Ser. No. 529,578, filed Feb, 23, 19.66, now abandoned for Ser. No. 806,015, also abandoned, while the thermally conductive relationship of the platens to the electrodes is discussed in detail by Harrison et al. in Ser. No. 304,910,'filed Aug. 27, 1963, now Pat. No. 3,392,058. The disclosures of the Holmes,

Patented Jan. 12, 1971 'ice Dantowitz, and Harrison et al. patent applications are incorporated by reference in this patent application.

My invention is directed to a discovery which avoids a disadvantage associated with the fuel battery disclosed by Holmes. When the Holmes fuel battery is operated on a fuel reactant, such as hydrogen, which contains small quantities of impurities, the impurities collect in the channels of the iiuid distributor and periodic purging is required, as is discussed in the Holmes patent application. Even if totally pure hydrogen could be Vobtained some substantial quantities of inerts would still eventually build up Within the fluid distributor channels as a result of nitrogen diffusion through the ion exchange membranes.

It is my recognition that inert liuids tend to collect in the multi-ply interconnected channels of the Holmes fuel battery construction to mask from the fluid reactant the electrodesegment next adjacent the purge outlet while l the other electrode segments remain relatively free of fluid inerts. As inerts accumulate over the surface of the masked electrode, the fuel cell formed by this electrode segment and the electrode segment mounted in directly opposed relation and in contact with air will be polarized. Polarization may even proceed to the point at which this cell is being electrically driven by the remaining cells of the battery. In this instance it is possible for electrolysis to occur which generates hydrogen at the electrode segment in contact with ambient air and oxygen at the electrode segment in contact with the inert uid, The generation of oxygen in the hydrogen containing channels causes burning on the hydrogen exposed electrode segments and total failure of the fuel battery as a power source follows soon thereafter.

It is an object of my invention to provide a process and apparatus which better distributes inert fluids between the electrode segments of a fuel battery so that one cell of the battery is not selectively polarized to the extent that electrolysis may occur.

This and other objects of my invention are, in one aspect accomplished by providing a fuel battery including electrolyte means including laterally spaced segments in contact with a first major face. Second electrode means including laterally spaced segments in contact with the second major face of the electrolyte means are mounted in opposition to the segments of the first electrode means. At least a portion ofthe segments are electrically connected in series, and means are provided for delivering a fluid reactant tothe first electrode means including an inlet means. My improvement resides in the delivering means including a portion cooperating with the electrolyte means and the first electrode means to define a distribution channel for the fluid reactant. The distribution channel includes a first course extending from the fluid inlet means across one of the segments to a remaining segment electrically connected to lie at a differing electrical potential and a second course extending from the remaining segment back to the one segment. The first and second courses are interconnected remote from the one segment only.

In another aspect my invention is directed to a process of generating electrical energy comprising providing an electrolyte element with a plurality of laterally spaced first electrode segments on one major face and a plurality of directly opposed second electrode segments on a second major face thereof. The segments are electrically connected in series. A first fluid reactant is permitted to contact the first electrode segments and a second fluid reactant is permitted to contact the second electrode segments. The first fluid reactant is directed from an inlet sequentially back and forth across the first electrode segments through `a plurality of serial related laterally spaced courses leading to an outlet from which fluid flow is FIG. l is. a 4 vertical sec` 'on of batteryaecording Vto my inyezntOn, with portions beingschematically indi- IG. 2 Iis is ,an.e1eva.tion.of anelectrolytes u cture 4with electrode segments mounted thereon@ .i. @FIG 4is anelevation showing -theinnerwface of.. al... distributor according to my invention;. 1 if, l. FIG..;5 is an elevation showing the inner face..of a conventional distributor; and ,s y FIG. 6 is a fragmentary elevation of an inner face of a modified distributor according to my invention.

Noting first FIG. l, a fuel battery 100 is shown having 25 a central mounting frame 102 formed of electrically insulative material. Ion exchange membranes 112 sealingly cooperate with the outer surfaces of the. frame to form a chamber 111. A fluid reactant inlet conduit 104 is shown communicating with the chamber and controlled by..a valve 106. A fluid reactant outlet conduit 108 also cornmunicates with the chamber and is controlled by a valve 110.

Each ion exchange membrane has mounted thereon a plurality of electrode segments 114. As shown in FIG. 3 35 the electrode segments are mounted by the ion exchange membrane in laterally spaced relation. FIG. 3 may be taken as showing either an inner or outer face of the membrane with the electrodes attached, since both are identical in appearance. The electrode segments on the inner face of each membrane are mounted in direct opposition to the electrode segments on the outer face of each membrane. Edge connecting strips 116 extend from one electrode segment around the edge of the membrane tothe electrode segment on the opposite face of the membrane ,one position removed. In this way the segments are electrically connected in series. An electrical potential develops between each electrode segment vand the segment mounted on opposition thereto equivalent to that developed by a singlefuel'cejll; Accordingly,-in`the 50 form illustrated each ion exchange 'membrane Ywith the electrode segments mounted thereon develops the Zpotential difference of live'fuel cells. The electrodefsegment '114a lying on each face of each ionexchange membrane is not connected to the remaining segments by strips 116, 55 but may be connected by electrical leads, notishown, -to terminals or to provide any-other type of electrical interconnection desired. Holmes, for example, connects the, electrode segments carried by four ,ion exchange membranes in series and connects oneelectrode .segment of each of two membranes to a terminal. of theyfuel battery. This particular structural feature of the .fuel Ybattery is not per se the subject matter of my invention and is more fully describedy in the applications of Dantowitz and Holmes. 'v l f' I Y Peripheral gaskets 118 seal between the outer edge vof the rnembranesand fluid distributors 120. 'Die distributors may be provided with heat transferlns 122'on their outerg, surface. A channel 124 is provided in the inner face of each distributor. Thepreferred relationship of the'dis- 70 tributorV to the electrode'segments -is best illustrated in FIG. 2. The ion exchange membrane'is'shown with the electrode segment 114 'mounted :in contact therewith. In 1 a preferred form illustrated the electrode segment includes a current collector screen embedded in an electro- 715 .ajseetional detailyofxthe shown .2157' fluid" may,emerge-.from-thedistributor, ine

mass. Two screens 132 and 134, preferably formed of dissimilar mesh size or having their axes skewed, overle the hydrophobic film. The inner surface of the distributor is provided with a thin, thermally conductive, electrically insulative film 136.

The layout of the channels in the inner faces of the distributors is best appreciated by reference to FIG. 4. In order to illustrate the relationship between the channels courses. In:.onefset .-of-v courses indicated-by reference numeral 1'42Lft'he u'idifreactaiitis l'directed"l in sequence frn theelectrode-#steginntrfthet-lefmfrthe distributor, as shown in FIG.; 4to the'ilghitl-hand electrode segment.

20, In hasecond set of courses 'designated'.'by reference Y nu- 'e'r'als`144 the fluid reactant moves fromitheI right-'hand electrode segment across the intervening segments to the left-hand .electrode` segment.- The first andsecond courses are connected end'to end as indicated yby reference nu- 'rn'eral 146. Thecou'rse 142 mostv remote-from the "inlet conduit means "is connected vto an outlet "conduit means 1 48 schematically illustrated as'being controlled by a valve means'150. The channels next adjacent'the outlet conduit means are shown by cross-hatchingvv to contain aninert fluid.

In generating electrical energy the electrode segments may be electrically connected in series, ambient air admitted' to the chamber-114 through the inlet conduit 104 t and exhausted through outlet lconduit 108, and 1a uid 'reactant such as hydrogen admitted to the channels of the distributors through inlet conduit means 14,0. To generate electricity the fuelv battery electrode segments are connectedacross anY electrical 4load in a manner. well vunderstoodby thosei skilled inthe art. Where' ambient air is' the 'oxidant it may be allowed to convectively circulate into contact with the -inner electrode segments. Hydrogen .leavingthe .inlet conduit means enters th channels124 and, specifically, the c ourse 142 thereof. .'lfhe hydrogen is then `transported sequentially from the eleci trode segment next adjacent the inlet conduit means yto the y,e le ctrj de Segment most remote vfrom thefluid `lllft mCUS- Ille hydrogendthen enters the second course '14,4 ofthe "channel by reason of the interconnection therebetween at and' isv'transportedfback from the' remote electrode segment to theele'ctrode segment next' 'adjacent 'the iiid l:inlet:'rrre'ans-.-Ii'1 this 'way the'hydrog'enfows'vbacle arid forth sequentially ac'r'oss theielectode segmentslft is' notedthat adjacent the' intermediately located v-electrode'segmentsthe courses-'of the lchannels-are free `-of interconnectionvso -that the hydrogen must flow longitudinally;of: the courses.

It is recognized that the hydrogen is 'not entirely'conlined to the channels. The channels Vmay bel looked upon as a primary fluid reactant distribution system. Fluid reactant is free to contact the electrode segments laterally of `thecoursesby diffusion through the interstices 0f vthe screens .132 and134. lAs the..uid;reactant traversesthe Courses it isbeing concurrently laterally diiiusedzintlo contactrywithlthe .electrode segments wherelit is. consumed eleffoqhemallyat la rateproportionalthe @lectrialsurrent being drawn from the fuel''battery. Accordingly, :whil'e'the 'illuid' reactant which emerges fri'r'l1 Athe inlet'con- `duit"`r'eans may contain only a'`sm'al'l concentration( yof Jineit -uid fili'g're'lients',v thispropor'ti''n "is'rr'u'ch h'i'gh'e'r'in v"therfluid that reaches tliec'oliises next'ladjacnttlie outlet condu'it'lm'eans. "If the` valve means 150is` 'initiallyilosed or adjusted so as to significantly restrict the rate-"at which rts willrc'ollect inthe coursesnext-adjacent thereto-ri It is a signiiicant feature of my invention that the fluid vinerts are spread in near uniform manner among the several velectrode :segments `lrIfhis means that lall of the electrode segments arev polarized tov about the same degree by the fluid inerts and that nofoneelectrode `segment is failing'to carryits' share of 'the electrical "load., Also, Athe chance of one cell of the battery becoming so highly polarizedf'as to be driven into electrolysis byfthe remaining cells is minimized. Another'significant advantage provided by-"myl series" connected courses is ".thatevery vportion of the channel is positivelypurged" during `start up and at purging intervals thereafter. lWith conventional, .multi-.ply interconnected'channels occluded portions of the :channels tend to be by-passedf rather'than purged. .This vmay be appreciated in considering rthe operation ofrm'y` fuel battery if water should be condensed at any point toblock or-v partially block one or more of the courses,- asmight readily 'occur-'by generalized orlocal cooling ofthe fuelbattery or some portion thereof.` The water wouldbemoved through the courses by thefluidreactant and laterally distributed over the surface 'of thelionnexchangeffmembrane where it may be readsorbed. With a conventional grid pattern of channels Jany water'condensed in the channels is `simply by-passed-by Vthe fiuid reactant v'anda-.portion of the electrode segments is accordinglymoretorles's permanently deactivatedf` Y v, 1 i. a i

"I The advantage of myinv'ention asregards distribution of inert fluids is best ap1; reciated byreference to FIKG. 5. The distributor 200 may be physically:substituted-for a distributor 120 'in the; fuel battery 100.lf1`he distributor 200 is provided with aipluralityfof platens 2,02 which are defined by intersecting sets `o`f vertical :channels 204 and horizontal channels 206,. T'Iflgre fluid reactant upon leaving the fluid inlet ,means 208 andtraversing the chaunels to the fluid outlet means 210 is then' free to ow through a-large number of parallel and Vrnulti-plyinterconnectedcourses. The result islasindicatedy by cross hatching 212; The Vfluid inerts then to accumulate almost' exclusiv'ely adjacent the' electrode segment1114 most remote from the fluid inlet conduit means. Thus; the improvement attributable to myzdistinctive fiuidreactant circulation pattern isreadily appreciated.` I v y ""`FIG."6 is a fragmentary view' of a' modified distributor 300 formed accordinguto myinventiorn'il'heruid inlet means 302 is connected'to ytvv'o parallel" han'nel's 3021 and 306 which are otherwise similar to the channel 124. The two channels are free of interconnection between the inlet and the outlet conduit means. This modification illustrates that it is not essential in order to obtain the advantages of my invention to entirely confine the fluid reactant to serially related channels. A combination of serially related and parallel channels may, if properly chosen in accordance with my teachings, serve equally as well.

While I have disclosed my invention with reference to certain preferred embodiments and uses, it is appreciated that various modifications of structure and usage will readily occur to those skilled in the art. It is considered undesirable to attempt to catalogue all possible obvious variations in construction and use. For purposes of illustration only, it is noted that while the electrolyte elements have been described as ion exchange membranes, it is possible to substitute a porous matrix containing an immobilized electrolyte. It is not necessary thatI rthe electrolyte element be either planar or rectangular as shown, but circular and cylindrical constructions could be readily devised without the exercise of invention. The fue'lbattery 100 is shown provided with two ion exchange membranes, but could be readily modified so as to incorporate one, three, or any number of ion exchange membranes. It is not essential that all of the electrode segments be electrically connected in series. Series-parallel combinations of interconnection may be desirable as well. The'use of screen or any other foraminous lateral distributor elements are not essential. Most 4fluid electrodes are suiciently porous as to allow some lateral diffusion of fiuid reactant from the channels. The foraminous elements allowing lateral diffusion are preferably coextensive with the area defined by the; gaskets 118, but may becoextensive with the individual electrode segments, if desired. The foraminous lateraldistributor elements may -be electrically conductive ornon-conductive, but are most preferably thermally conductive in most applications. If-.the -forarninous elements are formed of non-conductive materials, the thin fihn 136 may be omitted. The heat transfer fins are not essential. In a variant form means may be provided to circulate a .coolant adjacent the outer surface of the distributors. While ambient air has'been disclosed as a preferred oxidant, pureoxygen, hydrogen peroxide, or any other conventionalloxidantmay be substituted. In placev of hydrogen, ammonia, reformate, or hydrocarbons may be substituted, as is well understood in the art. The fluid .reactant which isthe oxidant may be fed to the distributors and the fluid'reactant which, is the fuel may be.V fed to the chamber 114, if desired. Still other variations may be undertal en.,It is accordingly intended lthat' the Ascope of my invention -bel determined with reference'to the following claims: *Y What VI claim -and desire to secure by Letters Patent of the United States is:

1. In a fuel battery comprising a plurality of fuel cells including electrolyte means having first and second major faces, first electrode means including a plurality of laterally paced segments in contact with first said first major ace, second electrode means including a corresponding plurality of laterally spaced segments in contact with said second major face, each segment of said second Aelectrode means being Imounted in opposition yto one Isegment of said first electrode means, at least a portion of said segments being electrically connected in series, and means for delivering a fiuid reactive to said first electrode means including an inlet means,

the improvement comprising 40 I fluid reactant delivering means for delivering reactant to all of the cells and ensuring that reactants are evenly distributed among all cells including a portion cooperating Work said electrolyte means and said o first electrode means to define a distribution channel for the fluid reactant including a first course extending from said fluid inlet means transversely across one of said segments to a remaining segment electrically connected to lie at a different electrical potential and across said remaining segment and a second course extending from and across said remaining segment back to and across said one segment, said first and second courses being interconnected at the end remote from said one segment only whereby said uid reactant passes back and forth across said segments a number of times so that fluid inerts are evenly distributed among all of the cells making up said battery.

2. A fuel battery according to claim 1 in which said electrolyte means is comprised of a porous matrix having an electrolyte immobilized therein.

3. A fuel battery according to claim 1 in which said electrolyte means is comprised of an ion exchange structure.

4.` A fuel battery according to claim 3 in which said electrolyte means is an ion exchange membrane.

5. A fuel battery according to claim 1 in which comprised of a multiplicity of courses extending over each of said first electrode segments, said courses being serially interconnected, whereby fluid reactant is serially and repeatedly directed across said electrode segments in lbeing distributed by said channel.

6. A fuel battery according to claim 1 in which said delivering means portion cooperating with said electrolyte meansand said first electrode means is thermally conductive and electrically insulative.

erated by said fuel battery.

8. A fuel battery according to claim 1 in which said first electrode means segments include means permitting diffusion of a portion of the fluid reactant laterally of said courses.

9. A fuel battery comprising a central mounting frame;

va plurality of ion exchange` .membraneseach` having an inner face sealingly cooperatingwith said.-rno,11nt Y ingframe to define a chamber foria first fluidfreactant and an .outer face in opppseclrelation lthg.=r=.ti

`means y-for controlling entry ofJ ithe n into the chamber, i y inner electrodeI means inlvudingwlaterally,spacedgsegt mentsincontactwiththeninner faces 1of said ion Vexchangetmsrl1bfams,,l outer electrode means includingvlaterally spalcedltsegy Wwments in contact with the outer faces :of= said ion exchange membranes, 4, l. -K each segment of said inner electrode `means being mounted in opposition to one segment of said outer electrode means, said inner and outer segments being electrically connected in series, y thermally conductive foraminous means for allowing lateral diffusion of a second fluid reactant overlying said outer electrode means, i a thermally conductive distributor overlying said outer electrode means associated with each of said ion exchange membranes,

a major portion of said distributors lying in thermally conductive relation with said foraminous means,

said distributors each being provided with at least one fluid distribution channel,

said one channel being comprised of first and second interleaved sets of courses.

first-s tluid-.rieagtant said first set of courses being provided with inlet portions courses of said first set by interconnecting said inlet1 f and outlet portions, and

wie

let and outlet portions. 10. A process of generating electrical energy comprising providing an electrolyte element with a plurality of laterally spaced first electrode segments on one major face and a plurality of directly opposed second electrode segments on a scond major face thereof, connecting the segments electrically in series, permitting a first fluid: eactant to contact the first elecfftrodexsgtente id s'ec'o'l nnidreactantato ebntact the second'eulctlo l A Y directing-'the fi tflui'd'retft'ritf "ar'i'ilet sequentiallytbaclx'an forthi aijos's'ftiiffirst electrode seguur, f. fw' z ".1, ments throughfa plurality of serially related laterally spaced coursesy leading yto Aan outlet, Y, v f normally restricting fluid flow from the outlet, connecting theelectrodemeans across an electrical consuming the yfi segments andthe se'hcndlljelidreactan'tat the second electrode sgnrentsjadd A l lcollecting an "inert fluid "nt'ramed inthe first fluid ref' 'ctant' inthe courses"leading'tothe` outlet Iso that the "-finert uid's'dis'tributed betweenthe rst lluid elec- Il. A process' according tollclair'n l110 additionally in- 'cluding'the'step of-'period i 'collected iner'tfluid.

lpurging Y' vthe A coursesfof References Cited Primary Euxaminer. 

